Vacuum Brake Booster: Service and Repair

BRAKE BOOSTER ASSY
REPLACEMENT
1. DRAIN BRAKE FLUID

NOTICE: Wash brake fluid off immediately if it adheres to any painted surface.

2. REMOVE AIR CLEANER ASSY
3. REMOVE BRAKE MASTER CYLINDER SUB-ASSY
SST 09023-00100





4. DISCONNECT VACUUM HOSE ASSY
a. Slide the clip and disconnect the vacuum hose from the brake booster assy.





5. REMOVE FRONT BRAKE TUBE NO.5
a. Using SST, remove the front brake tube No.5.
SST 09023-00100
6. REMOVE FRONT DOOR SCUFF PLATE LH
7. REMOVE COWL SIDE TRIM SUB-ASSY LH
8. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH
9. REMOVE BRAKE PEDAL RETURN SPRING
10. REMOVE PUSH ROD PIN
a. Remove the clip and push rod pin.
11. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Loosen the push rod lock nut and remove the push rod clevis.





12. REMOVE BRAKE BOOSTER ASSY
a. Remove the 4 nuts.
b. Pull out the brake booster assy.

NOTICE: Be careful not to damage the brake tubes and the wire harness.

13. REMOVE BRAKE BOOSTER GASKET
14. INSTALL BRAKE BOOSTER GASKET
a. Install a new brake booster gasket to the brake booster.





15. INSTALL BRAKE BOOSTER ASSY
a. Install the brake booster with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

NOTICE: Be careful not to damage the brake tubes and the wire harness.

16. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Install the push rod clevis and the push rod lock nut.

HINT: After adjusting the brake pedal height, torque the lock nut.

17. INSTALL PUSH ROD PIN
a. Apply lithium soap base glycol grease to the part indicated by an arrow.
b. Install the push rod pin and clip.
18. INSTALL BRAKE PEDAL RETURN SPRING
19. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL LH
20. INSTALL COWL SIDE TRIM SUB-ASSY LH
21. INSTALL FRONT DOOR SCUFF PLATE LH





22. INSTALL FRONT BRAKE TUBE NO.5
a. Using SST, install the front brake tube No.5.
SST 09023-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)





23. CONNECT VACUUM HOSE ASSY
a. Connect the vacuum hose to the brake booster assy and slide the clip.
24. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
SST 09737-00013, 09737-00020
25. INSTALL BRAKE MASTER CYLINDER SUB-ASSY
SST 09023-00100
26. FILL RESERVOIR WITH BRAKE FLUID
27. BLEED MASTER CYLINDER
SST 09023-00100
28. BLEED BRAKE LINE
29. INSTALL AIR CLEANER ASSY
30. CHECK FLUID LEVEL IN RESERVOIR
31. CHECK BRAKE FLUID LEAKAGE
32. CHECK AND ADJUST BRAKE PEDAL HEIGHT